Time has come for actual in car testing of AC compressor from Prius.
First i needed to determine proper rotation of compressor/pump. So its motor would rotate in correct direction. So i connected phase wires using cable clamps. I did this on desk. I used the same setup as in my car. I cut away the Prius connector and ordered 1x Volt aux pump connector assembly from Mouser.
Connector is TE HVA280. It can be ordered as assembly with various contacts and seals. P/N HVA280-3PXM
Exact P/Ns you can see here: https://www.te.com/commerce/DocumentDelivery/DDEController?Action=showdoc&DocId=Customer+Drawing%7F2103309%7FA1%7Fpdf%7FEnglish%7FENG_CD_2103309_A1_2103309-c_hva280_3pxm-xe_plug_drw.pdf%7FYHVA280-3PXM-A-000
Lebowski brain is fully capable of starting motor into the blue. I set parameters for Prius gen2 compressor.
Important settings for starting i summed up here:
| Erpm limits | eRPM=Mechanical RPM*Pole pairs | |
| Acceleration limiter forward | 6, 8 (12, 15) | need to reach at least 4.000rpm |
| Acceleration limiter reverse | 3, 5 | no need to run in reverse… |
| Regen rampup | 300, 4500 | |
| Direction change | 100 | 100erpm |
| Drive 2 | 100 | |
| Drive 3 | 2400 | need at least 2000erpm difference from drive 2 |
| Acc limiter | 1, 7 | slow limiter starting from 1000erpm/s |
| Current settings | ||
| Sensor transimpedance | 40 | Volt small inverter current sensors mV/A |
| Max motor currents | 25A | Set 20A for start |
| Max batt currents | 10A | Set 10A for start |
| FOC measurement | ||
| Perform impedance measurement | ||
| Inductance | 2550uH | Best is 2550uH |
| resistance | 600mOhm | Measured 60mOhm, best start at 600mOhm |
| miscellaneous | ||
| f) wiggle range: | 90 deg | |
| g) wiggle rate: | 180 Hz | |
Wiggle range and rate are important settings for reliable starting. So is good throttle calibration. Also i set throttle curve for gradual advancing with quick top later in the slide. I set throttle curve at 0.2 0.6 0.6
I joined the hoses and connectors to compressor. Do not forget to replace the Oring seals with new ones. Particularly the ones on the motor get chiped with sharp edges on assembly and there is good chance they will leak. Better to replace them when putting hoses back together.
I need to get correct oil to reliably drive compressor. Manufacturer Denso says its ND11 oil. Compressor needs 130g.
I need 134a gas too. Now i only neet to pressurize and test overnight.
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